Name of Plant Name of Chemical Chemical Storage & Dosing … · 2018-12-16 · of a flood in the...

O&M Manual for SX??? Page 1

NOTE: Sections highlighted in yellow are to be completed by the

Contractor supplying the Chemical dosing Unit

Name of Plant

Name of Chemical

Chemical Storage & Dosing System

Operation and Maintenance Manual

Sydney Water Facility No:

SX????

Installed at

Address Line 1

Suburb NSW Postcode

Sydney Water Contract No. ??????

Manufactured by

Name of Company

Address

Suburb NSW Postcode Phone: ??????

Service Telephone Name: mobile phone number


Contents CHAPTER 1 DESCRIPTION ........................................................................................................................ 4

1.1 General .......................................................................................................................................... 4

1.2 General description ....................................................................................................................... 4

1.3 Electrical ........................................................................................................................................ 5

1.4 Plumbing ....................................................................................................................................... 5

1.5 Chemical Dosing Unit Dimensions and Parameters ...................................................................... 6

CHAPTER 2 TECHNICAL DATA ................................................................................................................. 7

2.1 MANUFACTURERS TECHNICAL INFORMATION ........................................................................... 12

CHAPTER 3 PRINCIPLES OF OPERATION ................................................................................................ 13

3.1 Introduction ................................................................................................................................ 13

3.2 Responsibilities ........................................................................................................................... 15

3.3 Conditions ................................................................................................................................... 15

3.4 Dosing Profile ............................................................................................................................. 15

3.5 Control Modes ............................................................................................................................ 15

3.6 Specific Safety Requirements ..................................................................................................... 16

3.7 Environmental Aspects ............................................................................................................... 16

CHAPTER 4 OPERATING INSTRUCTIONS ............................................................................................... 17

4.1 Start up and pre start checks of the Chemical Dosing System for Automatic Mode ................. 17

4.2 Start up and pre start checks of the Chemical Dosing System for Manual Mode ..................... 19

4.3 Shutdown of the Chemical Dosing System for Manual Mode .................................................... 20

4.3 Shutdown of the Chemical Dosing System for Automatic Mode ............................................... 21

4.4 Chemical delivery procedure ...................................................................................................... 21

4.4 Emergency stopping in automatic mode .................................................................................... 24

4.5 Emergency stopping in manual mode ........................................................................................ 25

4.6 Abnormal Operation ................................................................................................................... 25

CHAPTER 5 INSTALLATION AND COMMISSIONING INSTRUCTIONS ..................................................... 26

5.1 Installation Procedures ............................................................................................................... 26

5.2 Pre-Commissioning and Commissioning Checklists .................................................................... 26

5.3 Commissioning Instructions ........................................................................................................ 26

CHAPTER 6 MAINTENANCE PLANS (PREVENTATIVE MAINTENANCE) .................................................. 27

6.1 Periodic Maintenance ................................................................................................................. 27


6.2 Spillage Cleaning Procedures ...................................................................................................... 29

6.2.1 Spill prevention .................................................................................................................... 29

6.2.2 Magnesium Hydroxide ......................................................................................................... 29

6.2.3 Ferrous Chloride ................................................................................................................... 29

6.2.4 Calcium Nitrate .................................................................................................................... 30

CHAPTER 7 MAINTENANCE PLANS (Overhaul / Major Maintenance) .................................................. 31

CHAPTER 8 TEST DATA, INSPECTION RESULTS AND TROUBLESHOOTING ............................................ 32

CHAPTER 9 PARTS LIST AND RECOMMENDED SPARES ........................................................................ 33

9.1 Equipment Supplier Details......................................................................................................... 33

9.2 Equipment Spare Parts Drawings and Details ............................................................................. 33

9.3 Recommended Spares ................................................................................................................ 33

Appendix A - DRAWINGS....................................................................................................................... 34

9.1 W.A.E. DRAWING REGISTER ........................................................................................................ 34

9.2 W.A.E. DRAWINGS ...................................................................................................................... 34

Appendix B – COMMISSIONING PLAN .................................................................................................. 35


CHAPTER 1 DESCRIPTION

1.1 General

This Chemical Storage & Dosing System is a complete storage and dosage system for (insert

name of chemical). Additionally referred to in the technical data specifications detailed in

Chapter 2.

1.2 General description

The chemical storage and dosing system is contained within a fully reinforced concrete

monolithic structure exhibiting a seamless connection between the floor and walls. This

structure comprises 2(two) separately accessible rooms. The design of which, along with epoxy

coating, ensures the bunded process room is capable of containing any unforeseen chemical

spills or leaks whether minor or catastrophic except for a leak in the water supply.

The roof of the structure has the ability of being removed, if required, to enable unimpeded

access to the process and control rooms, if either replacing a chemical storage tank or installing

large process equipment skids. Even without removing the roof the process room, the access

doors have a large enough opening whereby a storage tank up to 5KL capacity can be removed

through the door opening if required. The structures walls and roof have a smooth finish both

inside and outside and are painted to the approved Sydney Water colour.

The separately accessible, segregated control room has a viewing window to enable operators

to view and manage the control of process from a protected area. This room houses the process

control panel, RTU, site safety information in addition to operator manuals and drawings etc.

The bunded process room is accessed via external and internal stairs through double security

doors. The right hand door is interlocked to open first and provides the mounting for a safety

shower/eyewash which remains charged and ready for operation. The left hand door then can

be opened providing access to the storage tank filling point including the digital tank level

indicator.

Both the external and internal stairs for accessing the process room are suspended from the

door frame and feature a hinge arrangement, enabling the stair assemblies to pivot. Suspending

the stairs independently from the ground ensures they remain level irrespective of the slope of

the surrounding walkway and provides the benefit of swinging upwards to allow access

underneath for ease of cleaning.

A mobile work platform ladder is included for accessing both the manhole on the top of the

storage tank and to inspect the storage tank ultrasonic level transmitter. It also provides

operator access to unplug the roof mounted ventilation fans & lights from their switched outlets

in the event the roof requires removal.

Relevant safety signage is mounted on both doors, clearly visible when accessed by operators.

Both doors are supplied with a Deadlatch which is retrofitted with Sydney Water bi-lock barrels

when required.

The drain point for the bunded room is located on the front wall adjacent to the stairs. For ease

of access in the event of a bund high level, the process room bund isolation valve is located


externally to the structure within the delivery bund sump. The capacity of the bunded room

easily exceeds the storage tank capacity which ensures full containment of chemical in the

unlikely event of a catastrophic tank failure. System design parameters ensure that in the event

of a flood in the bunded area, normal operation can recommence once the bunded area has

been evacuated.

Storage tank and process equipment mounting arrangements employed in the construction of

the system minimise where possible the number of penetrations for fixings within the bunded

area to further ensure its long term containment integrity. All fixings required that are larger

than 6mm are made by way of chemical anchors.

1.3 Electrical

Installation of all the process electrical services and equipment is carried out in accordance with

Australian Standards with attention to ensure all equipment (IP) ratings are maintained. Cabling

is surface mounted and enclosed where possible within chemical resistant PVC ducting, conduits

and saddles are clearly labelled for individual circuit identification. Fans are fitted to the roof of

each room of the structure to ensure adequate ventilation; weatherproof lighting fixtures for

both rooms provide sufficient lighting to enable operation and maintenance day or night.

The ventilation fans are designed to operate when the site is accessed to provide operator

comfort when on-site. Both the ventilation fans and internal lighting are activated automatically

by limit switches on the access doors and the external flood light is operated by a manual switch

within the control room.

The door limit switches also automatically activate the ‘site attended’ input to the IICATS RTU

negating the need for a manned/unmanned switch to be manually activated.

Storage tank digital level display, high level warning flashing beacon and high level warning

klaxon are all situated on the storage tank fill line above the fill point in full view of the delivery

driver. The delivery truck pump power outlets are mounted within easy reach of the door way,

allowing the driver to remain outside the bund whilst connecting power and delivering product

into the storage tank. The truck pump power outlets are both interlocked to the tank high level

switch, automatically shutting off the power supply when a tank high level is reached. The high

level flashing light and warning siren is activated upon reaching a predetermined high level to

warn the driver of an imminent overfill occurring, this klaxon however can be muted by way of a

pushbutton on the control panel.

The electrical control designed into this system provides for both automatic and manual

operation. This will be covered in detail in Chapter 3.

1.4 Plumbing

Plumbing pipework used for the delivery of potable and non-potable water is (insert piping

material). An accessible roof mounted hose reel is installed within the process room to aid in

flushing dose lines and to enable washing down of the process room as well as the truck bund if

required.


All chemical process and delivery lines within the building are fabricated using Schedule 80 uPVC

pipe and fittings. The selection of pipe and fittings are determined by their suitable resistance to

(insert name of chemical).

Dosing pumps nominated for the system are (insert brand of pump) Pumps. The pumps have

been selected due to their suitable resistance to the effect of the dosed chemical, user

friendliness and the ability to easily deliver the required dose rates. Dosing pumps are installed

above the bund height in dosing cabinets to provide equipment protection in the event of a

bund flood occurring.

Operators are quickly alerted to any dosing pump leak or pipe rupture by way of a capacitive

level switch located directly beneath the dosing pumps in the dosing cabinet sump.

1.5 Chemical Dosing Unit Dimensions and Parameters A) Structure: Overall Length ?? metres Overall Width ?? metres Overall Height ?? metres External Wall Thickness ?? mm Internal Wall Thickness ?? mm Floor Thickness ?? mm Dry Weight ?? Tonnes Construction Materials ?? MPa reinforced concrete B) Process Room: Internal Length ?? metres Internal Width ?? metres Internal Height ?? metres (at lowest point) Bund Wall Height ?? mm Door Opening ?? metres Wide x ?? metres

Height C) Control Room: Internal Length ?? metres Internal Width ?? metres Internal Height ?? metres (at lowest point) Door Opening ?? metres Wide x ?? metres

Height D) Building Security Process Room Doors Double Steel Doors and

Frame Control Room Door Single Steel Door and Frame Locks Brand and type


CHAPTER 2 TECHNICAL DATA Details of the parameters of the dosing process.

Parameter Quantity/Requirements Units Type of dosing system; Flow paced/Diurnal rate - Type and properties of dosing chemical; (Insert name of chemical,

concentration, acid content etc.) -

Chemical supplier name and contact details - Location of the CDU (Insert street address, SPS number

etc.) -

Mobility requirement of the CDU Building; TRANSPORTABLE / PERMANENT - Rate of chemical dosing minimum ?? Litres/hour

Rate of chemical dosing maximum ?? Litres/hour Dilution/carrier water flow rate 10:1 with maximum chemical

dosage rate -

Delivery Bund Sump Pump

(if required)

Metres head

Pressure of available water supply for process water

?? Metres head

Pressure of available water supply for safety shower and eyewash;

?? Metres head

Advise whether H2S monitoring is fed back to the CDU;

YES / NO -

Diurnal minimum pressure of the pressure sewer main being dosed into;

?? Metres head

Diurnal maximum pressure of the pressure sewer main being dosed into;

?? Metres head

Delivery tanker size; ?? kilolitres Length /

Vehicle Type Maximum temperature of the delivered chemical;

?? °Celsius

Chemical tank storage size ?? kilolitres Minimum performance parameters, (for example, pH and dissolved sulphide levels expected before and after chemical dosing).

?? -

Protective coating system to be applied (external)

PUR-B or PSL for Anti Graffiti

ACL for Aesthetic

PUR-A for Coastal Environment

Protective coating system to be applied (bund floor and wall)

NOV (Novolac Epoxy)


Details of the major components of the dosing process. Storage Tank TNK01 Tank Content: ?? Manufacturer: ?? Model: ?? Part Number: ?? Effective Capacity ?? litres Inlet / Drain Diameters NB50 Discharge ?? (NB50 for Magnesium Hydroxide) Overflow Diameter NB80 Flanges ANSI 150 Vent NB50mm Access Manhole Removable 600mm dia. (600mm dia. if <5kL) Height of tanks ?? mm Nominal Diameter of tank ?? mm Circumference of tank when filled with chemical at top, middle and bottom.(This information is used to track the deformation of the tank over time.)

?? mm top ?? mm middle ?? mm bottom

Tank wall thickness (This information is used to track the deformation of the tank over time.)

?? mm

Mixer MIX?? (if fitted) Manufacturer: ?? Model: ?? Lower mixer paddle size and type 600mm Dia.3 blades angled at 45o Upper mixer paddle size and type 600mm Dia. 3 blades vertical orientation Part Number: ?? Maximum mixer rotating speed 200 RPM Motor Manufacturer ?? Motor Model ?? Motor speed and power 1380 RPM and1.5 kW 415V Mixer drive VSD Gearbox Manufacturer ?? Gearbox model No. ?? Gearbox ratio ?? : ?? Mass of Motor and Gearbox assembly ?? kg Shaft diameter 42mm OD Shaft support At gearbox and locator on floor of tanks Shaft removal Shaft is split with a flange. Level Transducer LTX01 Manufacturer: ?? Model: ?? Part Number: ?? Serial Number: ?? Power: 24VDC Loop Powered Signal output: 4-20mA 4mA output distance (tank empty 0%) ?? metres 20mA output distance (tank full 100%) ?? metres

Programmed Span distance ?? metres

Manufactures Range (default) ?? metres

High Level Setpoint LSA ??% of Full Scale. Low Level Setpoint LSC ??% of Full Scale


Dosing Pumps PMP10 & PMP20 Chemical Pumped: ?? Manufacturer: ??

Model: ??

Part Number: ??

Serial Numbers: PMP10: ?? PMP20: ??

Power: ?? KW @ ??Volts AC/DC Control Input: ?? Signal Output: ?? Minimum Dose Rate: ??Ltr/Hr @ ??Hz Maximum Dose Rate: ?? Ltr/Hr @ ??Hz Turndown: ??:1 Level Display LIX02 Manufacturer: ??

Model: ??

Part Number: ??

Serial Numbers: ?? Level Switches LSH01 & LSL01 Manufacturer: ??

Model: ??

Part Number: ??

Serial Numbers: ??

Power: 24VDC Control Input: ?? Control Output: Programmable Sump Pump PMP03(if Supplied) Manufacturer: ??

Model: ??

Part Number: ??

Serial Number: ??

Power: ?? KW @ 415Volts AC Control Input: Carrier Water Pump PMP??(if Supplied) Manufacturer: ??

Model: ??


Part Number: ??

Serial Number: ??

Power: ?? KW @ 415Volts AC Control Input: Potable Water Pump PMP??(if Supplied) Manufacturer: ??

Model: ??

Part Number: ??

Serial Number: ??

Power: ?? KW @ ??Volts AC Control Input: Level Switches LSH03 & LSL03 & LSHH03 (if supplied) (delete this table if no sump pump) Manufacturer: ??

Model: ??

Part Number: ??

Serial Numbers: ??

Power: 24VDC Control Input: ?? Control Output: Programmable Motorised Isolating Valve VLV05 Manufacturer: ??

Model: ??

Part Number: ??

Serial Numbers: ??

Power: ?? watts at 24VDC Control Input: ?? Control Output: ?? Carrier Water Solenoid Valve VLV55 Manufacturer: ??

Model: ??

Part Number: ??

Serial Numbers: ??

Power: ?? watts at 24VDC Control Input: ??


Control Output: ?? Flowmeter FTX02 Manufacturer: ?? Model: ?? Part Number: ?? Serial Number: ?? Power: 24VDC Loop Powered Signal output: 4-20mA Minimum measurable flow ?? Litres/hour Maximum measurable flow ?? Litres/hour Measurement Accuracy ??% of ??

Provide additional data tables for other major equipment items supplied.


2.1 MANUFACTURERS TECHNICAL INFORMATION NOTE: Information for preparation of this section. This note to be deleted when information is completed.

• Provide information from the manufacturers of the equipment. • Each page shall have the relevant equipment number on it. • Irrelevant pages or sales literature not to be included. • Where several models or sizes are covered on the information supplied the information

relevant to this chemical dosing unit shall be highlighted preferably in yellow. Insert data from equipment list here. Add general information for ball and NRV valves


CHAPTER 3 PRINCIPLES OF OPERATION

3.1 Introduction

The purpose of this standard operating procedure (SOP) is to provide personnel with a clear and

easy to follow set of operating instructions for the ?insert name of chemical? Chemical Dosing

System, SX??, at ?insert address?.

The Dosing System is designed to dose ?insert name or chemical? solution based on ??.

The chemical solution is delivered into the ?insert name of receiving sewer? by gravity/pressure

through a dedicated dosing line that is secondary contained to prevent any leak in the dosing line

escaping into the environment. The dosing pumps in this system are ?diurnal or flowpaced?

controlled ?insert type of pump? dosing pumps.

The dose rate for the system will be based on a pre-determined pattern to allow modifications if

desired. A facility will be provided to change the set point of this pre-determined pattern. This will

allow manual adjustment of dosing rates if desired by Sydney Water.

The system is designed to react with the sulphides in the sewage, change the pH of the sewage or

precipitate iron suphide, oxidise the sulphides (delete the non-applicable reactions), which in turn

prevents the release of Hydrogen Sulphide gas along the sewer main and in the downstream wet

wells, resulting in odour and corrosion problems.

SX?? consists of the following major components:

• ?size of tank?L Chemical Storage Tank (TNK01) Effective capacity

• Duty / Standby Dosing Pumps (PMP10, PMP20)

• Carrier water supply

The Chemical dosing process in Automatic is continuous diurnal or flow paced in operation, with the

dosing rate profile pre-determined by IICATS. Confirmation of dosing is through monitoring of the

tank level trend over time.

When the duty pump is called to run, an automatic ball valve (VLV05) on the storage tank initially

opens. Once the valve is opened, as determined by the valve limits switches (ZSC05 & ZSO05) the

duty pump then starts.

Once the pump is running, dilution water, which is flow rate adjusted through diaphragm valve

(VLV53) and controlled from solenoid (SOV55), is simultaneously delivered with the chemical

solution to the dose point. This aids in the mixing of the chemical into the sewerage. The dilution

water is set to run on for a preset time when the duty pump is called to stop to aid in flushing the

dose point.


Upon loss of any or all dosing permissives, the dosing pump stops, the automatic valve (VLV05)

closes and the system is inhibited from operation until receipt of another dosing permissive signal.

Dosing will also be inhibited in addition to IICATS alarms being raised if the Low-Level Switch (LSL01)

in the storage tank, Dosing Cabinet High Level Switch (LSH26) or Bund Flood Alarm (LSA26) is

activated. The dosing system will also be inhibited if there is a remote wet weather interlock active

within the network.

The Storage tank effective capacity will nominally provide >30 Days storage based on anticipated

flows. The frequency of chemical deliveries will be dependent on the dose rate. A re-order set point

(LSB01), determined by IICATS and referenced off the storage tank level transducer (LTX01),

generates a notification for the reorder of chemicals.

A high-level switch (LSH01) is fitted to the storage tank (TNK01) along with a high level set-point

(LSA01) derived from the level transducer (LTX01). If either is activated during filling of the storage

tank, this isolates the power to both the Single and 3-phase GPOs used by the chemical delivery

tanker to power the electrical unloading pump. Upon reaching a high level determined by either

(LSH01) or the level transmitter set point (LSA), an audible alarm (KLX01) and beacon (BEA01) will be

activated. The audible alarm (KLX01) can be muted from the control panel, however the beacon

(BEA01) remains on until the tank level falls below that of (LSH01) and (LSA01).

Other notable inclusions within this Chemical Dosing Unit:

• Door mounted Safety Shower and Eyewash (SEQ50)

• Internally mounted eyewash (SEQ51)

• Roof Mounted hose reel (UTY52)

• Fill point line isolation and drain valves (VLV01 & 02)

• Storage tank drain valve (VLV03)

• Dose line filter/strainers (STN01 and STN02)

• Multiple dose line flushing and drain valves

• Fill line mounted digital Storage Tank Level Indicator (LIX01)

• Secondary Storage Tank Level Indicator mounted on control panel (LIX02)

• Weather proof lighting including internal and external.

• Ventilation fans within each room.

• Safety Signage

This Standard Operating Procedure (SOP) covers the following operational tasks:

1. Start up of the chemical dosing unit in AUTOMATIC control.

2. Start up of the chemical dosing unit in MANUAL control.


3. Shutdown of the chemical dosing in MANUAL control.

4. Chemical delivery procedure.

Refer to Drawing No: SX?? P&ID Rev ?? for the P&ID layout of the chemical dosing process. (as

attached).

3.2 Responsibilities

• Treatment Operations is responsible for reviewing this SOP

• Treatment Operations is responsible for carrying out this SOP

3.3 Conditions

• Treatment Operations personnel are trained in this SOP

• This SOP is carried out on normal weekdays and whenever required

• Any equipment operating in an abnormal manner must be investigated and rectified.

• Any process reading that is out of range must be investigated and rectified

• Personnel comply with all safety requirements

• All equipment is tagged, if required, as per Sydney Water procedures

3.4 Dosing Profile

The Chemical Dosing Profile for SX?? is based on a diurnal or flow paced profile.

This profile is loaded by IICATs into the RTU and changed upon request from Treatment Operations

(OCR).

3.5 Control Modes

The dose rate will be controlled by either of two control modes.

Mode 1: Diurnal Control

Dosing shall be initiated by the RTU. When selected to run on diurnal speed control the dosing

pumps will run at an operator adjustable preset rate dependant on the time of day, this is operator

adjustable between 30-100%. Twenty four (24) setpoints, one for each hour of the day will be

available. There will be two diurnal profiles, one for weekdays and one for weekend use.

In order to fine tune the pump setpoints without continually adjusting each individual setpoint

within the diurnal profile, an operator adjustable Pumping Factor Multiplier (PFM1) (Adjustable 0-2,


default 1) and Pump Factor Offset (PFO1) (Adjustable -50% + 50%, default 0) shall be applied to the

diurnal profile in order to determine the required pump speed setpoint, as shown below.

Pump Speed % = (?? Setpoint * PFM1) + PFO1

Note: the pump running speed will be bounded by the minimum and maximum allowable pump

running speed. (Engineering Adjustable, programmed at 10-50Hz).

The pump will run at the speed preset by the operator for that time of day.

Mode 2: Flow Paced Control

Dosing shall be initiated by the RTU. When selected to run on flow paced control the dosing pumps

will run at an operator adjustable pre-set dose rate dependant on the flow in the sewer pressure

main. This is operator adjustable in terms of mg/litre.

Mode 3: Fixed Speed Control

Dosing shall be initiated by the RTU. When called to operate in this control mode, the pumps will run

at a fixed, engineering adjustable, speed (10-50Hz).

The initial Dose Rate will be as follows using ?insert chemical name? as the dosed chemical.

Chemical Dosing Rate: ..............................................?? L/Hr.

Carrier Water Flow Rate (nominal).............................?? L/Hr.

3.6 Specific Safety Requirements

• Refer to attached hazard identification and risk assessment and site specific hazard identification

• Ensure appropriate personnel protective equipment (PPE) is worn, minimum to include safety

shoes, gloves, eye protection, appropriate work clothing

• Ensure procedures for entry to confined spaces is followed

• Comply with occupational health and safety requirements

3.7 Environmental Aspects

• Failure to carry out this SOP may result in odour complaints in the vicinity of the site installation

and increased corrosion in the receiving waste water holding tank.


CHAPTER 4 OPERATING INSTRUCTIONS

4.1 Start up and pre start checks of the Chemical Dosing System for

Automatic Mode

Steps / Activity (AUTO) Photographs

1. Acknowledge and reset any alarms

on electrical control panel

Insert photograph here

2. Check level of MHL in storage tank via the Digital Level Indicator

(LIX01). Re-order chemicals if required.


3. Check all equipment and instruments are available for

operation and all LOTO tags are removed.


4. Ensure Non-Potable Water Valve

(VLV52) and Potable Water Valves (VLV50 & VLV51) are all ON.

Insert photograph/s here

5. Check operation of the door mounted safety shower and eyewash

(SEQ01)


6. Check operation of the internally mounted eyewash (SEQ02)


7. Check the following isolation valves are CLOSED:

• Suction manifold flushing and drain




valves (VLV19, VLV20, VLV?? & VLV22)

• Discharge manifold drain valve (VLV25)

• Dilution Water Solenoid bypass isolation valve (VLV56)

8. Check the following isolation valves are OPEN:

• Storage tank discharge isolation valve (VLV04)

• Dosing Pump 1 & 2 suction isolation valves (VLV11 & VLV21)

• Dosing Pump 1 & 2 discharge

isolation valves (VLV19 & VLV23)


9. Check the following isolation valves are OPEN:

• Dilution water Manifold Isolation

Valves (VLV54, VLV57 and VLV61)

Note: Dilution Water is flow rate adjustable

through (VLV53) and is set upon

commissioning to provide a dilution water to

chemical rate in the order of 10:1.


10.Ensure the field isolation switches for the dosing pumps (PMP10 &

PMP20) are switched to the ON position.




11. Ensure the “TANK IN SERVICE” selector switch is set to the IN

position.


12. Position the Dilution Water

Control Switch to AUTO.


13. Position the control selector switches for dosing pumps (PMP10 &

PMP20) to AUTO.

The duty dosing pump will then start automatically based on the IICATS

preset pump speed with reference to the dosing profile.


14. Visually confirm the dilution

water flow by looking at the rotameter (FIX54) float elevated to

the set flow position


15. Contact SOC to confirm that the dosing system is operating and that

no alarms have been raised.

4.2 Start up and pre start checks of the Chemical Dosing System for Manual

Mode

Steps / Activity (MAN) Photographs

1. Undertake steps 1 through to 15 as per startup in AUTOMATIC mode.

Position the control selector switches

for dosing pumps (PMP10 & PMP20) to MAN.



17. Press the required dosing pump

start Pushbutton.

The Automatic Valve (VLV05) will open and the pump will run at a

speed determined by the operator adjustable potentiometer on the

panel.

• Pump speed feedback is displayed on the VSD display in % of maximum

speed.


4.3 Shutdown of the Chemical Dosing System for Manual Mode


1. On the control panel, press the pump STOP button to stop the

system operation. The pump which has returned to running based on the

current diurnal profile now stops.

• This sends a signal to close the

automatic isolation valve (VLV05) and initiates the shutdown of the dilution water solenoid valve (SOV55). Local

indication of the valve position is provided by status lights on the

control panel. Note the lamp illumination to confirm valve

operation.


2. Contact SOC to confirm that the

dosing system has stopped operating and that no alarms have been raised.


4.3 Shutdown of the Chemical Dosing System for Automatic Mode


1. Position the control selector switches for dosing pumps (PMP10 &

PMP20) to OFF.

The duty dosing pump will then stop automatically.

• This sends a signal to close the

automatic valve (VLV05) and initiates the shutdown of the dilution water.

Local indication of the valve position is provided by status lights on the control panel. Note the lamp

illumination to confirm valve operation.


2. Contact SOC to confirm that the dosing system has stopped operating

and that no alarms have been raised.

4.4 Chemical delivery procedure

Steps / Activity Photographs

1. Unlock the Dosing system building,

fully open the doors and engage the captive door stops. This allows access

to the safety shower & eyewash (SEQ01), hose reel (UTY01), fill point

connection (VLV01) and High level alarm mute on the control panel.





2. Visually check the level of the storage tank (TNK01) using the fill

point mounted level display (LIX01) showing tank level in percentage

• The storage tank level can also be confirmed by viewing the secondary

level indictor (LIX02) mounted on the control panel.

3. Ensure Non-Potable Water Valve

(VLV52) and Potable Water Valves (VLV50 & VLV51) are all ON.


4. Check that the Safety Shower/

Eyewash (SEQ01) and hose reel (UTY01) are both operational.


5. Inspect the fill point connection for

damage and any sign of contamination, report prior to filling if evident.

6. Connect the chemical transfer hose to the camlock fitting.

7. Ensure the fill point drain valve (VLV02) is CLOSED.

8. Open the fill point isolation valve (VLV01)


9. Connect the transfer pump power cable from the delivery tanker to

either the Single Phase or Three Phase RCD Power Outlet located beside the fill point within the process

room.

10. Once connected, initiate the

power by pressing the START button.




11. Start the chemical transfer pump on the delivery tanker and commence chemical transfer to the storage tank.

12. Whilst filling, inspect the transfer hose for any leaks. If leaks are

detected, stop the chemical transfer pump immediately by pressing the STOP button located on the power outlet.

13. If the leak cannot be rectified on-site then cease the chemical transfer

operation.

14. Monitor the filling of the storage tank (TNK01) by viewing the level indicators (LIX01 or LIX02).

15. STOP the chemical transfer pump when the storage tank nears safe fill

capacity (90%), or when the chemical load has been delivered. Above 90%, the storage tank high level switch (LSH01) will be activated

which in turn cuts power to the truck power outlets. This is designed to prevent inadvertent overflows.

A flashing Beacon (BEA01) and audible warning (KLX01) will also be activated. The audible

warning can be muted from the control room switchboard however the flashing beacon and

power outlet interlock continues until the storage tank level drops below that of (LSH01)

16. Open the fill point drain valve (VLV03) to drain any residual

chemical from the fill line and transfer hose into a bucket.

17. Close the fill line isolation valve (VLV02)

18. Disconnect the chemical transfer

hose and replace the protective camlock cap on the fill point.

19. Disconnect the transfer pump

power cable from the truck power outlet.


20. Hose down any splashes or small spills in the Chemical Dosing Unit or

chemical unloading bay to ensure the area remains clean and tidy.



21. Close building doors, secure and depart site.

4.4 Emergency stopping in automatic mode


1a. Position the control selector switches for dosing pumps (PMP10 &

PMP20) to OFF. 1b. Or turn pump isolator switches to OFF.

The duty dosing pump will then stop

automatically.

• This sends a signal to close the automatic valve (VLV05) and initiates

the shutdown of the dilution water. Local indication of the valve position

is provided by status lights on the control panel. Note the lamp



2. Contact SOC to advise them off

the problem and check on alarm status.

3. Close isolating valves as required.


4.5 Emergency stopping in manual mode


1a. On the control panel, press the

pump STOP button to stop the system operation. The pump which

has returned to running based on the current diurnal profile now stops.

1b. Or turn pump isolator switches to OFF.

• This sends a signal to close the automatic isolation valve (VLV05) and

initiates the shutdown of the dilution water solenoid valve (SOV55). Local indication of the valve position is

provided by status lights on the control panel. Note the lamp



2. Contact SOC to advise them off the problem and check on alarm

status.

3. Close isolating valves as required.

4.6 Abnormal Operation

This plant should not be operated unattended in abnormal conditions.

Abnormal conditions include testing of the system, flushing of the system and dosing

to achieve an agreed outcome and should be done with operators present at all

times.


CHAPTER 5 INSTALLATION AND COMMISSIONING INSTRUCTIONS

5.1 Installation Procedures

Provide instructions for installations of the chemical dosing unit here including:

Footing and compacted base requirements.

Lifting arrangements

Positioning in place requirements

Methods of connecting the pipework. electrical power, controls and instrumentation

5.2 Pre-Commissioning and Commissioning Checklists

Detail checklist for pre-commissioning checks here.

Detail commissioning procedure and checklists here.

5.3 Commissioning Instructions

Refer to Commissioning Plan attached as Appendix B


CHAPTER 6 MAINTENANCE PLANS (PREVENTATIVE MAINTENANCE)

6.1 Periodic Maintenance

Item Plant or Equipment

Reference Operation Frequency

1 Dosing Pumps (PMP10 and PMP20)

Clean pumps of any dust or debris to allow adequate cooling.

Monthly

Relace diaphragms, valves or peristaltic hoses.

Annually

2 Manual Valves Check operation of manual valves not normally operated

Annually

3 Storage Tank TNK01

Check for leaks from the tank or piping

Each Visit

Inspect tank externally for visible defects

Annually

Inspect inside of tank via Manhole.

Annually

4 Carrier Water pumps (PMP?? and PMP??)

Potable Water pump (PMP??)

Check for leaks Each visit

Clean pump of any dust or debris to allow adequate cooling.

Monthly

5 Storage Tank Mixer MIX?? if fitted

Check for vibration and gearbox oil level.

Monthly

6 Loading Valve (PCV??), Pulsation Dampener (PD??), Pressure Relief Valves (PRV?? and PRV??).

Replace diaphragms.

Annually

7 Flow switch alarm (FSA??)

Check operation Annually


8 Pressure indicators (PIX??)


9 Pressure Relief Valves (PRV?? and PRV??)


10 Rotameter (FIX??) Check operation Annually

11 Controls Panel 24V Battery and

Level Transmitters and motorised valves 24V Battery

Check battery condition Annually

Replace Batteries 3 yearly

12 Electrical Power and Control Cabinets

Check and clean Annually

13 Emergency Shower, eyewashes and hosereel

Inspect and clean Each visit

14 Control Panel Indication Lamps

Activate Control Panel “Lamp Test” Function to indicate any faulty lights. Replace if necessary

Annually.

15 Doors, Hinges and Locks Lubricate Hinges and locking mechanisms with suitable penetrating grease or similar. Lubricate lock barrels with Graphite powder or similar

Annually.

16 Ventilation Fans Clean Roof mounted ventilation fans of all debris, dust etc to maintain airflow within structure

Annually

17

Sump Drain Valve and Pipework

Prevent blockage of the bunded room drain valve and pipework by avoiding

Monthly.


hosing any rubbish into it. Sweep floor and remove all material that could block the drain prior to hosing down area.

18 Internal and external Bunds

Sweep down to remove leaves, debris etc. Do not hose into the sumps.

Monthly

Inspect for damage to linings.

Annually

19 External Sump Inspect for damage to linings.

Inspect for damage and corrosion of pump (if fitted), valves, pipes and instruments

Annually

20 General Check doors, lighting, door open alarm, vent fans, leaks, condition of fill point Camloc.

At each visit

6.2 Spillage Cleaning Procedures

Delete or add as relevant

6.2.1 Spill prevention

Spillage or leakage of chemicals should be avoided during filling and maintenance work by locating a

bucket or drip tray under the location where a spill or leak might occur (EG storage tank fill point)

and disposing of the chemical into the storage tank if clean or offsite to a suitable location if

contaminated.

6.2.2 Magnesium Hydroxide

Magnesium hydroxide spills and leaks should be allowed to dry out and be swept up and removed as

a powder/solid. Magnesium Hydroxide should not be hosed down as this leaves a residue on the

surfaces it comes in contact with.

6.2.3 Ferrous Chloride

Ferrous Chloride spills should be lightly hosed down into the nearest sump taking care to not to

splash the chemical onto any surface not treated with an epoxy coating.


6.2.4 Calcium Nitrate

Calcium Nitrate solution spills should be lightly hosed down into the nearest sump taking care to not

to splash the chemical onto any surface not treated with an epoxy coating. If the Calcium Nitrate

dries out to a powder care should be taken as the dust is an irritant and can ignite combustibles

(paper, wood or oil).


CHAPTER 7 MAINTENANCE PLANS (Overhaul / Major Maintenance)

The following excerpts from the equipment and instrument suppliers’ manuals detail the procedures for undertaking major periodic maintenance and troubleshooting.

Procedures include:

Item Plant or Equipment

Reference Operation Frequency

1 Storage Tank TNK01

Message diameter of full tank. Compare with original diameter (no greater than 2% bigger than original)

Empty tank and inspect for cracks, opaqueness, and damage to inlet/outlet nozzles.

10 Yearly

List additional procedures here

Attach equipment suppliers information for major maintenance here.


CHAPTER 8 TEST DATA, INSPECTION RESULTS AND

TROUBLESHOOTING

Insert documents for:

Concrete Structure Inspection and Tests Plans

Letter from Structural Engineer confirming acceptance of the Structure Re-enforcing.

Test reports from the Concrete Supplier

Process Room Bund Hydrostatic Test

Bund Epoxy Coating

Storage Tank Hydrostatic Certificate

Switchboard Inspection and Test Plans.

Electrical Fitout Inspection and Test Plans

Pipework & Mechanical Fitout Inspection and Test Plans

Pipework installer’s certificate

Dosing Pumps Configuration

VSD Programming Settings (configuration) for (dosing pumps if required)

Equipment, Instruments and Drives Inspection Checklists

Calibration Certificates

FAT Test Results

SAT Test Results

Attach equipment suppliers’ information for troubleshooting here.


CHAPTER 9 PARTS LIST AND RECOMMENDED SPARES

Insert Parts list here

9.1 Equipment Supplier Details

Supplier Phone Fax/email address Street Address

Insert Details here

9.2 Equipment Spare Parts Drawings and Details

Insert any suppliers information here E.G. exploded diagrams, tank details including nozzles and

manholes etc.

Provide an exploded drawing of the dosing pump here showing enough detail to allow for regular

wearing part replacement and including descriptions and part numbers of replaceable parts.

9.3 Recommended Spares

Insert list of recommended spare parts for 2 years operation, suppliers and recommended stock

levels.


Appendix A - DRAWINGS

9.1 W.A.E. DRAWING REGISTER

Drawing Reference Description

Insert Details here

9.2 W.A.E. DRAWINGS

Attach all Work as Executed Drawings here.


Appendix B – COMMISSIONING PLAN

Attach Commissioning Plan here.

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